Web packaging machines with variable depth forming

ABSTRACT

A packaging machine is for forming a product cavity in a web including a forming die box defining a recess into which the product cavity is formed. An insert is axially movable in the recess to thereby vary a depth of the recess. A variable depth mechanism selectively moves the insert to vary the depth of the recess. The packaging machine includes a latching mechanism that moves the forming die box into and between a first position in which the forming die box is spaced apart from the die box base and a second position in which the forming die box is supported by the die box base.

CROSS-REFERENCE TO RELATED APPLICATION

The present application is based on and claims priority to U.S.Provisional Patent Application Ser. No. 62/241,359 filed Oct. 14, 2015,the disclosure of which is incorporated herein by reference.

FIELD

The present disclosure relates to web packaging machines for packaging aproduct between upper and lower webs.

BACKGROUND

The following patents are incorporated herein by reference in entirety:

U.S. Pat. No. 7,490,448 discloses a form-fill-seal web packaging systemthat includes a pressure monitor at the sealing station to monitor asealing pressure. A bladderless actuator effects relative movement ofdies and applies the sealing pressure.

U.S. Pat. No. 7,607,279 discloses a web packaging system that provideseasy access and changing of tooling. The changing of tooling therebychanges a product receiving cavity pocket in a lower web.

U.S. Pat. No. 8,181,432 discloses a web packaging system that provideseasy access and changing of a forming plug tooling.

SUMMARY

This Summary is provided herein to introduce a selection of conceptsthat are further described herein below in the Detailed Description.This Summary is not intended to identify key or essential features fromthe claimed subject matter, nor is it intended to be used as an aid inlimiting the scope of the claimed subject matter.

In certain examples, a packaging machine for forming a product cavity ina web includes a forming die box that defines a recess into which theproduct cavity is formed, an insert that is movable in the recess tothereby vary a depth of the recess, and a variable depth mechanism thatselectively moves the insert to vary the depth of the recess.

In certain examples, a packaging machine for forming a product cavity ina web includes a forming die box that defines a recess into which theproduct cavity is formed, a die box base that supports the forming diebox, and a latching mechanism that selectively moves the forming die boxinto and between a first position in which the forming die box is spacedapart from the die box base and a second position in which the formingdie box is supported by the die box base.

In certain examples, a method for forming a product cavity in a webincludes providing a forming die box that defines a recess into whichthe product cavity is formed, positioning an insert in the forming diebox such that the insert is axially movable in the recess to therebyvary a depth of the recess, actuating a variable depth mechanism toselectively move the insert to vary the depth of the recess, and thenforming the product cavity in the web.

BRIEF DESCRIPTION OF THE DRAWINGS

Examples are described with reference to the following drawing figures.The same numbers are used throughout the drawing figures to referencelike features and components.

FIG. 1 is an example web packaging machine.

FIG. 2 is a perspective view of an example forming station of the webpackaging machine having a forming die box in a staging position and aguide track assembly in an extended position.

FIG. 3 is a perspective view of the forming station of FIG. 2 having theforming die box in a first position and the guide track assembly in aretracted position.

FIG. 4 is an enlarged view of the forming station of FIG. 2, the formingdie box in the first position.

FIG. 5 is an enlarged view of the forming station of FIG. 2, the formingdie box in a second position.

FIG. 6 is a side view of the forming station of FIG. 2 including aframing assembly movable between a first lowered position and a secondforming position, the forming die box and a die box base move axially(as depicted in dashed lines) when the framing assembly moves to thesecond forming position.

FIG. 7 is a cross sectional view of the forming station depicted in FIG.2 through a middle of the forming die box, the forming die box is in thesecond position and a variable depth mechanism extending into aninterior vacuum space.

FIG. 8 is an enlarged cross sectional view of the forming die boxdepicted in FIG. 2 through a recess of the forming die box.

FIG. 9 is an example system of the packaging machine.

DETAILED DESCRIPTION OF THE DRAWING

In the present disclosure, certain terms have been used for brevity,clearness, and understanding. No unnecessary limitations are to beimplied therefrom beyond the requirement of the prior art because suchterms are used for descriptive purposes only and are intended to bebroadly construed. The different apparatuses, systems, and methodsdescribed herein may be used alone or in combination with otherapparatuses, systems, and methods. Various equivalents, alternatives,and modifications are possible within the scope of the appended claims.

Packaging machines for packaging food products between two webs ofelastic materials are known in the food packaging industry. Often, thepackaging machines form a product cavity in at least one of the webs tohold the food product. The product cavity is formed by a forming die boxthat defines a recess into which the product cavity is formed. Theforming die box often must be changed to form and/or accommodatesize/dimension requirements for different product cavity sizes. Forexample, a forming die box having recesses with a 2.0 inch recess depthmay be changed with a forming die box having recesses with a 4.0 inchrecess depth. The process of changing the forming die box usuallyrequires that the packaging machine be shut down in order for theforming die box to be removed and/or the web to be cut and peeled away.In other examples, the recess depth can be changed by manually insertingor removing plates or blocks into the recess (e.g. a 1.0 inch plate isinserted into the recess of the forming die box to decrease the depth ofthe product cavity 1.0 inch).

Changing the forming die box and/or the recess depth disadvantageouslyrequires operator interaction and shut-downs of the packaging machinewhich lead to lost packaging time and inefficiencies. The inventor hasrecognized these problems and has endeavored to provide apparatuses forchanging the depth of product cavities formed in a web by a packagingmachine. The present disclosure provides apparatuses and methods forallowing simplified, user-friendly, and automated recess depth changefor forming die boxes.

FIG. 1 depicts an indexing motion packaging machine 2 that includes aweb transport conveyor 4 transporting a web 6 of flexible packagingmaterial from upstream to downstream through a series of stationsincluding a forming station 10 that forms at least one product cavity 7in the web 6, a loading station 12 that places food product P in theproduct cavity 7, and a closing station 14 that closes and/or seals thepocket with another web of flexible packaging material.

Referring to FIGS. 2-3, the forming station 10 includes a die box base20 that is fixedly coupled to a frame assembly 30 (further describedherein below) of the packaging machine 2. The die box base 20 includes aperimeteral surface 22 that corresponds to and abuts a perimeteralsurface 42 on a forming die box 40 (further described herein below). Thedie box base 20 also defines at least one hole 24 (see FIG. 8) throughwhich an engagement member 92 (further described herein below) extends.

The forming station 10 includes the forming die box 40 which isconfigured to define at least one recess 44 in the web 6, into which theproduct cavity 7 is formed. A bottom surface of the recess 44 and/or thedepth of the recess 44 is defined by an insert 60 (further describedherein below) which is received in the recess 44. The forming die box 40includes a shelf 46 (see FIG. 8) that radially projects into the recess44 to axially support the insert 60 in the forming die box 40 (i.e. theshelf 46 prevents the insert 60 from falling through the recess 44 andout of the forming die box 40). The forming die box 40 also defines theperimeteral surface 42 that corresponds to and abuts the perimeteralsurface 22 of the die box base 20. The number of recesses 44, the shapeof the recess 44, the depths of the recesses 44, the recess depths,and/or other dimensions of the recess 44 can vary. In the exampledepicted in FIG. 2, six rectangular recesses 44 are depicted. A handle48 is coupled to the forming die box 40 to assist the user in moving theforming die box 40. Reference is made to the incorporated U.S. Pat. No.7,607,279 for further explanation of movable die boxes.

The forming die box 40 is moveable into and out of the forming station10 by a guide track assembly 70 that is configured to support theforming die box 40. The guide track assembly 70 allows the forming diebox 40 to be moved between a staging position (see FIG. 2) such that theforming die box 40 can be easily removed (e.g. lifted) from the formingstation 10 by an operator and a first position (see FIGS. 3-4) in whichthe forming die box 40 is axially above the die box base 20. The guidetrack assembly 70 includes a pair of rails 72 having rollers 74 thatreduce friction between the forming die box 40 and the guide trackassembly 70 as the forming die box 40 is moved on the guide trackassembly 70. The guide track assembly 70 is movable between a retractedposition (see FIG. 3) in which the rails 72 are substantially verticaland adjacent to the frame assembly 30 and an extended position (see FIG.2) such that the rail members 82 are substantially horizontal andsupport the forming die box 40 in a staging position (see FIG. 2) whichis offset from the packaging machine 2. When loading the forming die box40 into the forming station 10, an operator moves the guide trackassembly 70 to the extended position (see FIG. 2) and places the formingdie box 40 onto the rails 72. The operator then pushes the forming diebox 40 along the rails 72 into the first position (see FIG. 3). Once theforming die box 40 is in the first position, the operator rotates theguide track assembly 70 back to the retracted position (see FIGS. 3-4).When unloading the forming die box 40 from the forming station 10, theoperator moves the guide track assembly 70 to the extended position andthen pulls the forming die box 40 into the staging position (see FIG.2). The operator can then remove the guide track assembly 70. Referenceis made to the incorporated U.S. Pat. No. 7,607,279 for further detailsof the guide track assembly 70. In certain examples, a locking plate 38(see FIG. 5) secures the forming die box 40 to the die box base 20.

Referring to FIGS. 4-5, the forming die box 40 is axially movable withinthe forming station 10 by a latching mechanism 80 that secures theforming die box 40 to the forming station 10 by moving the forming diebox 40 into and out of engagement with the die box base 20. The latchingmechanism 80 moves the forming die box 40 into and between the firstposition (see FIGS. 3-4) in which the forming die box 40 is spaced apartfrom the die box base 20 and a second position (see FIG. 5) wherein theforming die box 40 is supported by the die box base 20 (or otherwisemates with or engages with the die box base 20). That is, the latchingmechanism 80 axially moves the forming die box 40 such that theperimeteral surface 22 of die box base 20 is supported by theperimeteral surface 42 of the forming die box 40. When the forming diebox 40 is in the first position (see FIGS. 3-4), the forming die box 40is freely laterally movable away from the die box base 20, and when theforming die box 40 is in the second position (see FIG. 5) the formingdie box 40 is supported by the die box base 20. The forming die box 40is supported by the die box base 20 in a manner that creates a fluidtight seal and define an interior vacuum space 28 (see FIG. 8) therebetween, and the fluid tight seal is created when the perimeteralsurface 22 of the die box base 20 abuts the perimeteral surface 42 ofthe forming die box 40. The forming die box 40 and the die box base 20cooperate with a cover 26 (see FIG. 6) (described further herein below)positioned above the web 6 at the forming station 10 to create a vacuumin the interior vacuum space 28 and thereby form the product cavity 7under force of vacuum. In certain examples, a gasket 47 (see FIG. 8) isincluded along the perimeteral surface 22 of the die box base 20 tocreate a vacuum tight seal between the forming die box 40 and the diebox base 20.

The latching mechanism 80 includes a rail member 82 for axiallysupporting the forming die box 40 in the first position (see FIGS. 3-4).The rail member 82 includes a sloped surface 84 configured allow theforming die box 40 to slide along the rail member 82 when the formingdie box 40 moves between the staging position (see FIG. 2) and the firstposition (see FIGS. 3-4). The latching mechanism 80 includes aneccentric member 86 that is configured to rotate to thereby move therail member 82 such that the forming die box 40 moves between the firstposition (see FIGS. 3-4) and the second position (see FIG. 5). That is,rotation of the eccentric member 86 moves the rail member 82 therebymoving the forming die box 40 into and between the first position (seeFIGS. 3-4) and the second position (see FIG. 5). For example, theeccentric member 86 is rotatable in a first direction such that the railmember 82 axially moves downward and the forming die box 40 moves fromthe first position (see FIGS. 3-4) to the second position (see FIG. 5);and the eccentric member 86 is rotatable in a second direction oppositethe first direction such the rail member 82 axially moves upward and theforming die box 40 moves to the from the second position (see FIG. 5) tothe first position (see FIGS. 3-4). The shape of the eccentric member 86can vary. In one example, the eccentric member 86 is a semicircle disk.The latching mechanism 80 includes a handle 88 by which an operator canmanually rotate the eccentric member 86.

Once the forming die box 40 is positioned in the second position (seeFIG. 5), the packaging machine 2 can form the product cavity 7 in theweb 6. Referring to FIG. 6, the forming die box 40 (which is in thesecond position) and the die box base 20 are supported by a movable baseplate or frame assembly 30 which moves during operation of the packagingmachine 2. The frame assembly 30 is movable between a lowered positionaxially below the web 6 such that the forming die box 40 is axiallybelow the web 6 and the web 6 is allowed to advance; and a formingposition such that the forming die box 40 engages the web 6 to therebyform the product cavity 7 in the web 6 (the forming die box 40 isdepicted in dash-doubledot-dash line weight in FIG. 6 when the frameassembly 30 is in the forming position). When the frame assembly 30 isin the forming position, the cover 26 (which is stationary and fixedlymounted to the packaging machine 2 at the forming station 10) cooperateswith forming die box 40 to create a vacuum in the interior vacuum space28 and thereby form the product cavity 7 in the web 6. Vacuum equipment(not shown and known in the prior art) coupled to the die box base 20creates the vacuum in the interior vacuum space 28 such that the productcavity 7 is formed in the web 6. The cover 26 optionally includes a plugassist mechanism having a plug member, a heat plate, and/or the like.The frame assembly 30 is moved between the lowered position and theforming position by lift arms 32 that are rotated by an actuator 35(e.g. a servo motor) and belt 34 (see movement arrows A which depictmovement of the lift arms 32 and the belt 34).

Referring to FIGS. 7-8, the inserts 60 received in the forming die box40 are shown in greater detail. As described above, the bottom surfaceof the recess 44 is defined by the insert 60 which is received orpositioned in the recess 44 such that the insert 60 is axially movablein the recess 44 to thereby vary the depth of the recess 44 or therecess depth. The insert 60 includes a projection 62 that radiallyextends from the insert 60 to contact the shelf 46 of the forming diebox 40 (see FIG. 8) such that the insert 60 is supported in the recess44 (i.e. the projection 62 of the insert 60 contacts the shelf 46 toprevent the insert 60 from axially moving through the forming die box 40in one axial direction). The insert 60 includes an upper end 63 and alower end 64 opposite the lower end 64, and the projection 62 is locatednearer the upper end 63 than the lower end 64 such that the lower end 64is axially below the shelf 46 of the forming die box 40 when the shelf46 contacts the projection 62 of the insert 60. The projection 62 has acurved surface 66 that defines a bottom perimeteral fillet of the recess44. The insert 60 can change the shape of the recess 44 and/or thenumber of the recesses 44 defined in the forming die box 40 (i.e. aninsert 60 can fill the entire recess 44 such that the number of productcavities 7 formed by the forming die box 40 is reduced (e.g. a formingdie box 40 with six recesses 44 receives two inserts 60 that completelyfill two recesses 44 such that the number of product cavities 7 formedby the forming die box 40 is reduced to four)). Further, a variabledepth mechanism 90 (described herein) is capable of moving the insert(s)60 such that the number of product cavities 7 formed by the forming diebox 40 is reduced.

The forming station 10 includes the variable depth mechanism 90 thatmoves the insert 60 to thereby vary the depth of the recess 44. Thevariable depth mechanism 90 includes at least one engagement member 92that is slideably received in the hole 24 of the die box base 20. Theengagement member 92 comprises a first end 93 that extends into theinterior vacuum space 28 defined by the forming die box 40 and the diebox base 20 and a second end 94 opposite the first end 93. Theengagement member 92 contacts the insert 60 to thereby move the insert60 and vary the depth of the recess 44. In certain examples, the firstend 93 of the engagement member 92 comprises a plate 96 configured tocontact the insert 60 and/or multiple inserts 60 received in therecess(es) 44 of the forming die box 40. In operation, axial movement ofthe first end 93 of the engagement member 92 causes axial movement ofthe insert 60. In certain examples, the engagement member 92 must returnto a rest position (see the plate 96 depicted in solid line on FIG. 7)before the forming die box 40 can be moved to the staging position (seeFIG. 2) (i.e. the engagement member 92 and/or the plate in an engagementposition (see the plate 96 depicted in dashed line on FIG. 7) preventsthe forming die box 40 from moving from the first position (see FIGS.3-4) to the staging position (see FIG. 2), and vise versa). The variabledepth mechanism 90 can be adapted for use with any type (e.g. size,shape) of forming die box 40.

The variable depth mechanism 90 includes a drive shaft 98 that isrotatably coupled to the die box base 20 and a platform member 100 thatis coupled to the drive shaft 98 and the second end 94 of the engagementmember 92. In one example, the platform member 100 includes screwthreads and the drive shaft 98 includes screw threads that mate and/orengage with the screw threads of the platform member 100. An actuator104 selectably rotates the drive shaft 98 such that the platform member100 axially moves along the drive shaft 98 to axially move the insert 60(e.g. when the drive shaft 98 is rotated by the actuator 104, theplatform member 100 axially moves which causes the engagement member 92to move). In the example depicted, the actuator 104 is a servo motorwhich selectively moves a belt 105 to thereby rotate the drive shaft 98.As the servo motor actuates in a first servomotor direction, the belt105 moves in a first belt direction causing the drive shaft 98 to rotatein a counterclockwise direction; and when the drive shaft 98 actuates ina second servomotor direction, the belt 105 moves in a second beltdirection causing the drive shaft 98 to rotate in a clockwise direction.In certain examples, the drive shaft 98 is rotatably supported by afixed member assembly 108 that supports and allows rotation of the driveshaft 98. The fixed member assembly 108 being fixed with respect to thedie box base 20.

Referring to FIG. 9, the packaging machine 2 includes a controller 120configured to control the components and devices of the packagingmachine 2, including the components described herein. The controller 120is configured to control movement of the web 6 via the web transportconveyor 4; actuation of the actuator 33 to move the lift arms 32 andthe frame assembly 30, as described above; and/or the actuator 104 ofthe variable depth mechanism 90, as described above. The controller 120is part of a system 118 included with the packaging machine 2. Thesystem 118 includes a user input device 122 that allows the operator toinput information into the system 118 to control the depth of the recess44 in the forming die box 40. For example, the operator can input intothe user input device 122 a selected recess depth of 3.0 inches suchthat the controller 120 sends appropriate signals (via wired or wirelesscommunication links 130) to the actuator 104 of the variable depthmechanism 90. The actuator 104 then axially moves the engagement member92 to axially move the insert 60 within the recess 44 such that theinsert 60 defines the depth of the recess 44 at the selected recessdepth.

The controller 120 includes a processing system 124, storage system 126,and software 128. The processing system 124 loads and executes software128 from the storage system 126. When executed by the controller 120,the software 128 directs the processing system 124 to operate to carryout the methods described herein.

It should be understood that one or more software application modulescould be provided within the software to carry out the same operation.Similarly, while description as provided herein refers to a controller120 and a processing system 124, it is to be recognized thatimplementations of such systems can be performed using one or moreprocessors, which may be communicatively connected, and suchimplementations are considered to be within the scope of thedescription.

The processing system 124 can comprise a microprocessor and othercircuitry that retrieves and executes software 128 from storage system126. Processing system 124 can be implemented within a single processingdevice but can also be distributed across multiple processing devices orsub-systems that cooperate in existing program instructions. Examples ofprocessing system 124 include general purpose central processing units,applications specific processors, and logic devices, as well as anyother type of processing device, combinations of processing devices, orvariations thereof.

The storage system 126 can comprise any storage media readable byprocessing system 124, and capable of storing software 128. The storagesystem 126 can include volatile and non-volatile, removable andnon-removable media implemented in any method or technology for storageof information, such as computer readable instructions, data structures,program modules, or other data. Storage system 126 can be implemented asa single storage device but may also be implemented across multiplestorage devices or sub-systems. Storage system 126 can further includeadditional elements, such as a controller, capable of communicating withthe processing system 124.

Examples of storage media include random access memory, read onlymemory, magnetic discs, optical discs, flash memory, virtual memory, andnon-virtual memory, magnetic sets, magnetic tape, magnetic disc storageor other magnetic storage devices, or any other medium which can be usedto storage the desired information and that may be accessed by aninstruction execution system, as well as any combination or variationthereof, or any other type of storage medium. In some implementations,the storage media can be a non-transitory storage media. In someimplementations, at least a portion of the storage media may betransitory. It should be understood that in no case is the storage mediaa propagated signal.

User input device 122 can include a mouse, a keyboard, a voice inputdevice, a touch input device, a motion input device, and othercomparable input devices and associated processing elements capable ofreceiving user input from a user. Output devices such as a video displayor graphical display can display an interface further associated withembodiments of the system and methods as disclosed herein. Speakers,printers, bells and other types of output devices may also be includedin the user input device 122. The user input device 122 may display thesystem 118 on a display screen, and/or may announce it via a speaker.

In certain examples, the forming station 10 includes a sleeve 101 thatis coupled to the die box base 20 to support and seal the engagementmember 92 with the die box base 20 as it slides in the hole 24 (seeFIGS. 7-8). In certain examples, the vacuum cups 102 are coupled to thedie box base 20 and configured to create the vacuum in the interiorvacuum space 28 (see FIG. 7).

In certain examples, a packaging machine for forming a product cavity ina web includes a forming die box that defines a recess into which theproduct cavity is formed, an insert that is movable in the recess tothereby vary a depth of the recess, and a variable depth mechanism thatmoves the insert to vary the depth of the recess. The variable depthmechanism includes an engagement member that contacts the insert tothereby move the insert and vary the depth of the recess. A die box basesupports the forming die box and defines an interior vacuum spacetherebetween, and the die box base further defines a hole that slidablyreceives the engagement member. The engagement member comprises a firstend that extends into the interior vacuum space to thereby move theinsert and vary the depth of the recess. The engagement member includesa second end opposite the first end. The variable depth mechanism caninclude a drive shaft, a platform member coupled to the drive shaft andthe second end of the engagement member, and an actuator thatselectively rotates the drive shaft such that the platform member movesalong the drive shaft and the engagement member moves the insert. Thevariable depth mechanism includes a fixed member assembly that supportsand allows rotation of the drive shaft. The fixed member assembly isfixed with respect to the die box base. In certain examples, theactuator is a servo motor. In certain examples, a computer controllercontrols the servo motor to thereby rotate the drive shaft.

In certain examples, a latching mechanism that moves the forming die boxinto and between a first position in which the forming die box is spacedapart from the die box base and a second position in which the die boxbase supports the forming die box. When in the first position, theforming die box is freely laterally movable away from the die box base,and when in the second position the forming die box is supported by thedie box base. The forming die box has a perimeteral surface, and the diebox base has a perimeteral surface that corresponds to and abuts theperimeteral surface of the forming die box in the second position. Thelatching mechanism has a rail member that supports the forming die boxand an eccentric member such that rotation of the eccentric member movesthe rail member thereby moving the forming die box into and between thefirst position and the second position. In certain examples, thelatching mechanism has a handle configured to rotate the eccentricmember. The forming die box includes a shelf that projects into therecess to support the insert in the forming die box, and the insert hasa projection that radially extends from the insert and is supported bythe shelf. The insert has an upper end and a lower end opposite theupper end such that the projection is positioned nearer the upper endthan the lower end such that the lower end is axially below the shelf ofthe forming die box when the projection is supported by the shelf. Incertain examples, the projection has a curved surface that defines abottom fillet of the recess.

In certain examples, a packaging machine for forming a product cavity ina web includes a forming die box that defines a recess into which theproduct cavity is formed, a die box base that supports the forming diebox, and a latching mechanism that moves the forming die box into andbetween a first position in which the forming die box is spaced apartfrom the die box base and a second position in which the forming die boxis supported by the die box base. The latching mechanism furthercomprises an eccentric member such that rotation of the eccentric membermoves the forming die box into and between the first position and thesecond position. The latching mechanism includes a rail member forsupporting the forming die box, wherein the rail member axially moveswhen the eccentric member rotates.

In certain examples, a method for forming a product cavity in a webincludes providing a forming die box that defines a recess into whichthe product cavity is formed, positioning an insert in the forming diebox such that the insert is axially movable in the recess to therebyvary a depth of the recess, actuating a variable depth mechanism to movethe insert to vary the depth of the recess, and forming the productcavity in the web. The method can include rotating a drive shaft thatmoves a platform member of the variable depth mechanism such that theengagement member moves.

In the present description, certain terms have been used for brevity,clearness and understanding. No unnecessary imitations are to be impliedtherefrom beyond the requirement of the prior art because such terms areused for descriptive purposes only and are intended to be broadlyconstrued. The different apparatuses, systems, and methods describedherein may be used alone or in combination with other apparatuses,systems, and methods. Various equivalents, alternatives andmodifications are possible within the scope of the appended claims.

What is claimed is:
 1. A packaging machine for forming a product cavityin a web, the packaging machine comprising: a forming die box defining arecess into which the product cavity is formed; an insert that isaxially movable in the recess to thereby vary a depth of the recess; anda variable depth mechanism that selectively moves the insert to vary thedepth of the recess.
 2. The packaging machine according to claim 1,wherein the variable depth mechanism comprising an engagement memberthat contacts the insert to thereby move the insert and vary the depthof the recess.
 3. The packaging machine according to claim 2, furthercomprising a die box base that supports the forming die box and definesan interior vacuum space there between, wherein the die box base furtherdefines a hole through which the engagement member extends; and whereinthe engagement member comprises a first end that is disposed in theinterior vacuum space and configured move the insert to vary the depthof the recess.
 4. The packaging machine according to claim 3, whereinthe engagement member further comprises a second end that is oppositethe first end; and wherein the variable depth mechanism furthercomprises: a drive shaft; a platform member coupled to the drive shaftand the second end of the engagement member; and an actuator thatselectively rotates the drive shaft such that the platform member movesalong the drive shaft and the engagement member moves the insert.
 5. Thepackaging machine according to claim 4, wherein the variable depthmechanism further comprises a fixed member assembly that supports andallows rotation of the drive shaft, wherein the fixed member assembly isfixed with respect to the die box base.
 6. The packaging machineaccording to claim 4, wherein the actuator is a servo motor; and furthercomprising a computer controller that controls the servo motor tothereby rotate the drive shaft.
 7. The packaging machine according toclaim 1, further comprising: a die box base that supports the formingdie box; and a latching mechanism that moves the forming die box intoand between a first position in which the forming die box is spacedapart from the die box base and a second position in which the die boxbase supports the forming die box.
 8. The packaging machine according toclaim 7, wherein in the first position the forming die box is freelylaterally movable away from the die box base; and wherein in the secondposition the forming die box is supported by the die box base.
 9. Thepackaging machine according to claim 8, wherein the forming die boxcomprises a perimeteral surface; and wherein the die box base comprisesa perimeteral surface that corresponds to and abuts the perimeteralsurface of the forming die box in the second position.
 10. The packagingmachine according to claim 7, wherein the latching mechanism comprises arail member that supports the forming die box and an eccentric member,wherein rotation of the eccentric member moves the rail member therebymoving the forming die box into and between the first position and thesecond position.
 11. The packaging machine according to claim 10,wherein the latching mechanism further comprises a handle configured torotate the eccentric member.
 12. The packaging machine according toclaim 1, wherein the forming die box comprises a shelf that projectsinto the recess and supports the insert in the forming die box.
 13. Thepackaging machine according to claim 12, wherein the insert comprises aprojection that radially extends from the insert and is supported by theshelf.
 14. The packaging machine according to claim 13, wherein theinsert further comprises an upper end and a lower end opposite the upperend; wherein the projection is positioned nearer the upper end than thelower end such that the lower end is axially below the shelf of theforming die box when the projection is supported by the shelf.
 15. Thepackaging machine according to claim 13, wherein the projection has acurved surface that is configured to define a bottom fillet of therecess.
 16. A packaging machine for forming a product cavity in a web,the packaging machine comprising: a forming die box defining a recessinto which the product cavity is formed; a die box base that supportsthe forming die box; and a latching mechanism that moves the forming diebox into and between a first position in which the forming die box isspaced apart from the die box base and a second position in which theforming die box is supported by the die box base.
 17. The packagingmachine according to claim 16, wherein the latching mechanism furthercomprises an eccentric member; and wherein rotation of the eccentricmember moves the forming die box into and between the first position andthe second position.
 18. The packaging machine according to claim 17,wherein the latching mechanism further comprises a rail member forsupporting the forming die box, wherein the rail member axially moveswhen the eccentric member rotates.
 19. A method for forming a productcavity in a web, the method comprising: providing a forming die box thatdefines a recess into which the product cavity is formed; positioning aninsert in the forming die box, wherein the insert is axially movable inthe recess to thereby vary a depth of the recess; actuating a variabledepth mechanism to move the insert to vary the depth of the recess; andforming the product cavity in the web.
 20. The method according to claim19, further comprising: wherein the variable depth mechanism comprisesan engagement member that contacts the insert to thereby move the insertand vary the depth of the recess; and further comprising rotating adrive shaft that moves a platform member such that the engagement membermoves.